Pro-Form XP 160 831.28645.1 User manual

ELLIPTICAL EXERCISER
User’s Manual
CAUTION
Read all precautions and instruc-
tions in this manual before using
this equipment. Keep this manu-
al for future reference.
Serial Number
Decal
(on underside
of frame)
Model No. 831.28645.1
Serial No.
• Assembly
• Operation
• Maintenance
• Part List and Drawing
Sears, Roebuck and Co., Hoffman Estates, IL 60179

TABLE OF CONTENTS
WARNING DECAL PLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
IMPORTANT PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
BEFORE YOU BEGIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
HOW TO USE THE ELLIPTICAL EXERCISER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
EXERCISE GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
PART LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
EXPLODED DRAWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
ORDERING REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover
90 DAY FULL WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover
2
WARNING DECAL PLACEMENT
The warning decal shown here has
been applied in the location shown.
If the decal is missing or illegible,
call 1-888-533-1333 and request a
free replacement decal. Apply the
decal in the location shown. Note:
The decal may not be shown at
actual size.

3
1. Before beginning any exercise program,
consult your physician. This is especially
important for persons over the age of 35 or
persons with pre-existing health problems.
2. It is the responsibility of the owner to ensure
that all users of the elliptical exerciser are
adequately informed of all precautions.
3. Your elliptical exerciser is intended for home
use only. Do not use your elliptical exerciser
in a commercial, rental, or institutional set-
ting.
4. Keep your elliptical exerciser indoors, away
from moisture and dust. Place your elliptical
exerciser on a level surface, with a mat
beneath it to protect the floor or carpet.
Make sure that there is enough clearance
around your elliptical exerciser to mount,
dismount, and use it.
5. Inspect and properly tighten all parts regu-
larly. Replace any worn parts immediately.
6. Keep children under age 12 and pets away
from your elliptical exerciser at all times.
7. Your elliptical exerciser should not be used
by persons weighing more than 275 lbs.
(124 kg).
8. Wear appropriate exercise clothes when
exercising; do not wear loose clothes that
could become caught on your elliptical exer-
ciser. Always wear athletic shoes for foot
protection.
9. Hold the handgrip pulse sensor or the upper
body arms when mounting, dismounting, or
using your elliptical exerciser.
10. Keep your back straight while using your
elliptical exerciser; do not arch your back.
11. The pulse sensor is not a medical device.
Various factors, including the user’s move-
ment, may affect the accuracy of heart rate
readings. The pulse sensor is intended only
as an exercise aid in determining heart rate
trends in general.
12. When you stop exercising, allow the pedals
to slowly come to a stop.
13. If you feel pain or dizziness while exercising,
stop immediately and cool down.
14. Use your elliptical exerciser only as
described in this manual.
WARNING: To reduce the risk of serious injury, read all important precautions and
instructions in this manual and all warnings on your elliptical exerciser before using your elliptical
exerciser. Sears assumes no responsibility for personal injury or property damage sustained by or
through the use of this product.
IMPORTANT PRECAUTIONS

4
BEFORE YOU BEGIN
Thank you for selecting the new PROFORM®XP 160
elliptical exerciser. The PROFORM XP 160 elliptical
exerciser provides a wide array of features designed
to make your workouts at home more effective and
enjoyable.
For your benefit, read this manual carefully before
you use the elliptical exerciser. If you have ques-
tions after reading this manual, please see the back
cover of this manual. To help us assist you, note the
product model number and serial number before con-
tacting us. The model number and the location of the
serial number decal are shown on the front cover of
this manual.
Before reading further, please familiarize yourself with
the parts that are labeled in the drawing below.
Handgrip Pulse Sensor
Handlebar
Wheel
Pedal
Console
Water Bottle Holder*
Accessory Tray
Leveling Foot
Leveling Foot
Fan
*No water bottle is included

5
M8 Split
Washer (72)–2
M4 x 16mm
Self-tapping
Screw (79)–10
M8 x 42mm Bolt
(71)–4
M10 x 20mm x
1mm Washer
(81)–2
M4 x 16mm
Screw (86)–4
M10 Spacer
(76)–2
M6 x 35mm Phillips
Screw (87)–8
M6 Split
Washer (88)–8
M10 x 23mm Shoulder
Screw (80)–2
M4 x 13mm
Washer (93)–2
M10 x 25mm
Washer
(94)–10
M8 Nylon
Locknut (96)–4
M10 Nylon
Locknut (97)–2
Star Washer
(92)–3
M10 x 20mm Patch
Screw (91)–10
Wave Washer
(98)–8
M8 x 16mm Patch
Screw (95)–3
M8 x 48mm Patch
Screw (78)–2
M10 x 62mm Patch Bolt (89)–4 M10 x 78mm Patch Screw (90)–2
ASSEMBLY
Assembly requires two persons. Place all parts of the elliptical exerciser in a cleared area and remove the
packing materials. Do not dispose of the packing materials until assembly is completed. In addition to the
included hex keys, assembly requires a Phillips screwdriver , an adjustable
wrench , and a rubber mallet .
As you assemble the elliptical exerciser, use the drawings below to identify small parts. The number in parentheses
below each drawing is the key number of the part, from the PART LIST near the end of this manual. The number
following the parentheses is the quantity needed for assembly. IMPORTANT: Some small parts may have been
pre-assembled. If a part is not in the parts bag, check to see if it has been pre-assembled. If a part is
missing, call 1-888-533-1333.

6
1.
Orient the the Front Stabilizer (35) as shown.
Attach the two Wheels (25) to the Front Stabilizer
with two M10 x 62mm Patch Bolts (89) and two
M10 Nylon Locknuts (97).
Attach two Feet (26) to the underside of the
Front Stabilizer (35).
2. Have a second person tip the Frame (2) back-
ward. Attach the Front Stabilizer (35) to the
Frame with two M10 x 78mm Patch Screws (90).
97
26
26
1
2
2
89
89
25
25
35
90
35
To make assembly easier, read the
information on page 5 before you begin
assembling the elliptical exerciser.
3. Orient the Base (1) near the Frame (2) as
shown. See the inset drawing. Attach two Feet
(26) to the underside of the Base.
Have a second person tip the Frame (2) forward.
Insert the Base (1) into the Frame. Attach the
Base with two M10 x 62mm Patch Bolts (89), two
M10 Spacers (76), two M8 x 48mm Patch
Screws (78), and two M8 Split Washers (72).
2
89
1
72
78
3
1
76
26
26

7
4. Have a second person hold the Upright (6) near
the Frame (2) as shown.
Pull the Wire Harness (48) out of the Frame (2)
and insert it upward through the Upright (6). Do
not let the Wire Harness fall into the Upright; use
a piece of tape or an elastic band to hold the
Wire Harness in place until step 12.
Insert the Upright (6) into the Frame (2). Attach
the Upright with three M8 x 16mm Patch Screws
(95) and three Star Washers (92). Avoid pinch-
ing the Wire Harness (48) between the
Upright and the Frame.
6
4
95
95
92
2
95
92
48
5. Identify the Left Roller Leg (12), which is marked
with a “Left” sticker. Orient the Left Roller Leg as
shown near the left Crank Arm (36).
Apply a small amount of the included grease to
both sides of a Wave Washer (98). Also, apply
grease to the Roller (22) on the Left Roller Leg
(12); spread the grease evenly around the
Roller.
Slide the Wave Washer (98) onto the left Crank
Arm (36). Next, slide the Left Roller Leg (12)
onto the Crank Arm and set the Roller (22) on
the Base (1). Attach the Left Roller Leg with an
M10 x 20mm Patch Screw (91), a Crank Axle
Cap (30), and an M10 x 25mm Washer (94).
Repeat this step to attach the Right Roller
Leg (21) to the right Crank Arm (not shown).
536
1
30
94
98
22
Grease
91 12
21
Grease

8
6. Identify the Left Handlebar (8), which is marked
with a “Left” sticker. Insert the Left Handlebar into
one of the Handlebar Legs (11) as shown.
Attach the Left Handlebar (8) with two M8 x
42mm Bolts (71) and two M8 Nylon Locknuts
(96). Make sure that the Nylon Locknuts are
inside the hexagonal holes.
Assemble the Right Handlebar (not shown)
and the other Handlebar Leg (not shown) in
the same way.
11 71
8
96
6
Hexagonal
Hole
Hexagonal
Hole
7. Position an Inner Handlebar Cover (18) and an
Outer Handlebar Cover (19) around the Left
Handlebar (8) as shown.
Attach the Inner and Outer Handlebar Covers
(18, 19) with three M4 x 16mm Self-tapping
Screws (79) and an M4 x 13mm Washer (93).
Start all three Self-tapping Screws before
tightening them.
Repeat this step for the Right Handlebar (not
shown).
7
19
18 79
79
8
93

9
8. Apply a generous amount of grease to the Pivot
Axle (65) and insert it into the Frame (2).
Attach the two Frame Covers (17) to the Frame
(2) with four M4 x 16mm Screws (86) as shown.
886
86
65
17
17
2
Grease
9. Apply a small amount of grease to both sides of
a Wave Washer (98). Slide the Wave Washer
onto the left side of the Pivot Axle (65). Next,
slide the Left Handlebar (8) onto the Pivot Axle
as shown.
Attach the Left Handlebar (8) with an M10 x
23mm Shoulder Screw (80) and an M10 x 20mm
x 1mm Washer (81).
Repeat this step to attach the Right
Handlebar (9) to the Pivot Axle (65).
9
98
9
81
8
80
65
Grease

10
10. Identify the Left Pedal (13) and the Left Pedal
Leg (14), which are marked with “Left” stickers,
and orient them as shown.
Attach the Left Pedal (13) to the Left Pedal Leg
(14) with four M6 x 35mm Phillips Screws (87)
and four M6 Split Washers (88). Start all four
Phillips Screws before tightening them.
Repeat this step to attach the Right Pedal
(not shown) to the Right Pedal Leg (not
shown).
10
88 88
13
14
87
87
11. Apply a generous amount of grease to two Pedal
Leg Axles (32). Insert one Pedal Leg Axle into
the bottom of the left Handlebar Leg (11). Insert
the other Pedal Leg Axle into the Left Roller
Leg (12).
Apply a small amount of grease to both sides of
two Wave Washers (98). Place a Wave Washer
on each Pedal Leg Axle (32).
Orient the Left Pedal Leg (14) as shown, and
slide it onto the Pedal Leg Axles (32). Attach the
Left Pedal Leg to the left Handlebar Leg (11) with
two M10 x 20mm Patch Screws (91), two Axle
Caps (31), and two M10 x 25mm Washers (94).
Attach the Left Pedal Leg (14) to the Left Roller
Leg (12) with two M10 x 20mm Patch Screws
(91) and two M10 x 25mm Washers (94); do not
overtighten the Patch Screws. The Legs (11,
14, 12) must be able to pivot freely.
Repeat this step for the Right Pedal Leg (not
shown).
31
91
14 94
91
94
32
94
11
91
12
94 91
31
32
11
Grease
98
Grease
98